Bondo and window cutting

[dfigravity]

Hey guys...ok so I came across a small case that I am currently working on...ordered a nice shiny piece of aluminum for a new faceplate etc etc...so the stupid side panel has a recessed portion that is used as a "handle" or sorts to take the side off...

http://i26.photobucket.com/albums/c126/dfigravity/IMG_1287.jpg

It's not very deep...

http://i26.photobucket.com/albums/c126/dfigravity/IMG_1288.jpg


My question is...can I bondo over this thing, and then cut something out of it? This is what I want to cut out of the side
http://i26.photobucket.com/albums/c126/dfigravity/web_afg_040405_018.jpg

I dont think it will overlap the part I want to bondo too much...but just in case, has anyone had any problems with cutting something you've filled with bondo?

[Drum Thumper]

As long as you cut relatively slow, and don't mind the possibility of having to do a bit of touchup, I don't see any problems with cutting through the bondo. In all actuality, it cuts quite easily. Just be sure to wear proper safety gear (glasses, dust mask, etc).

[vastonecat]

That panel looks like it should be metal so if you REALLY have a problem with the bondo then you could cut out that depression and get someone to weld a new panel in place. After that you should have no problems with any cut you make. Keeping in mind that the actual weld will be stronger than the metal around it, and so harder to cut with a dremel. The only real problem I would have with going ahead and cutting the Bondo is the thickness of the panel at that portion of the window cuts.
Hope this helps and nice design.

[dfigravity]

ok...I was afraid that the bondo would crack/crumble while being cut. That's not a bad idea about the weld either, but it's a little more that I want to take on for this mod. I'm going to print out the design full size and see just how much of it is over the depression. Thanks for your input guys!

[a.Bird]

You could bang her right flat out. I would cut like so:



_______
|\ """--,,_
| \ \
| \ \
| | |
| | |
| | |
| / /
| / _ /
|/______,,,--""


_______
|\ """--,,_
|X\ \
|XX\ \
|XX|________ |
|XXXXXXXXXXX>-------|
|XX|¯¯¯¯¯¯¯¯ |
|XX/ /
|X/ _ /
|/______,,,--""


Then slowly hammer the depression flat and either weld or bondo the gaps left. I apologize for the crudeness of the diagram, I'm at work and limited to this reply form window and character map.